Method and Apparatus for Application of Mortar

ABSTRACT

A spray head for spraying mortar is provided. The spray head includes a mortar supply pipe and a spinning head positioned at an outlet point of the mortar supply pipe, the spinning head directing mortar supplied from the mortar supply pipe in a direction substantially perpendicular to the direction of travel of mortar in the mortar supply pipe. An air intake for receiving air is further provided, the air being employed to spin the spinning head pneumatically. Finally, a material input port is provided for inputting material to be combined with the mortar in the mortar supply pipe at the outlet point of the mortar supply pipe.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication Ser. Nos. 61/440,527, filed Feb. 8, 2011 to Scott Gesicki etal., titled “Method and Apparatus for Application of Mortar”, and61/447,303, filed Feb. 28, 2011 to Scott Gesicki et al,. titled “Methodand Apparatus for Application of Mortar”, the entire contents of theseapplications being incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to the application of mortar, and morespecifically to the application of a mortar formed of cementatiousmaterials or polymer or other mortar in a spray on application,preferably employing inventive centrifugal spinner equipment andaccompanying inventive delivery equipment.

BACKGROUND OF THE INVENTION

Application of mortar or other rehabilitation materials on the inside ofconcrete or metal pipes, other concrete or other surfaces to beremediated often takes too much time, the equipment is too expensive,and current processes fail to provide a satisfactory product. Similarissues may present themselves when such pipe is formed of corrugatedmetal or other metal pipes, or any other pipe surface. The issues mayrange from full structural failure, partial structural failure, cracks,exfiltration of materials from the pipe, infiltration of materials intothe pipe, separation of joints, etc.

FIG. 13 depicts a typical spinner head assembly. As is shown in FIG. 13,a nozzle 700 spins about an axis 710, comprising a hose or othermaterial delivery device. Upon delivery of material at a high speed,such material is preferably ejected at a high velocity from spinninghead 720, including rear spinner disc 714, thus generating a materialdischarge point 712. Further shown is an air intake 730 and a spinnerbody 740. The air is used to spin the spinner head in a pneumaticfashion. The spinner head is preferably attached to a sled to positionthe spinner head at the correct point in the pipe. The sled alsocontrols the movement of the spinner head parallel to the pipe. Such asystem fails to provide a high velocity material discharge system, thusresulting in potentially uneven application of material,

Therefore, it would be desirable to provide an apparatus that overcomesthe drawbacks of the prior art.

SUMMARY OF THE INVENTION

In accordance with one or more embodiments of the present invention, oneor more inventive apparatuses and methods are preferably provided forproperly positioning a spinner head in a location in which mortar is tobe deployed, and for delivering various materials to the spinner head,for placement of the spinner head in a desired location, and for use ofan inventive spray head with the inventive spinner head. An inventiveapparatus in accordance with an embodiment of the invention may comprisean inventive centrifugal spinner for application of rehabilitationmaterial in a pipe, other remediation area, or the like to a desiredplacement point or application area. Sprayers of any other sort may alsobe applicable in accordance with one or more alternative embodiments ofthe invention.

In accordance with another embodiment of the invention, a method may beprovided in which a layered or laminated spray of rehabilitationmaterial may be provided, thus allowing for a single application of anydesired thickness, and preferably from ¼″ or less to as much 6″ inchesthick or more in some circumstances.

In accordance with another embodiment of the invention, an inventivemethod for transporting equipment utilized for application ofrehabilitation material through a pipe or other confined space in amanner that monitors and meters appropriate application volumes may beprovided. Mixers for mixing various materials may be provided in thevicinity of a spinner head applying the material, and may further beposition on an inventive sled used for supporting the mixer and sprayhead.

In yet another embodiment of the invention, a method for safelyconveying, power, and supplying air, electric, raw rehabilitationmaterial, water and other material to an application point through aspecially designed harness that encapsulates and protects the componentsof such a delivery system may be provided.

In accordance with a further embodiment of the invention, an inventivecentrifugal spinner is preferably provided that may allow for theintroduction of high volume, high pressure air and/or other materials ata discharge point, which in turn allows the rehabilitation material tobe projected or propelled at a high velocity. This high velocitymaterial may be projected or propelled in a manner that achieves a highimpact of the rehabilitation material on a desired surface, thusresulting in a desired packing of the material thereon. In turn, therehabilitation material preferably achieves a high density at its pointof application, positively affecting rehabilitation material (i.e.mortar) performance and durability. This durability and performanceincrease may include one or more of an improved resistance to chemicalattack, an improvement of general imperviousness of the appliedmaterial, an improvement in the compressive strengths of the material,and achievement of a greater diameter placement.

Still other objects and advantages of the invention will in part beobvious and will in part be apparent from the specification anddrawings.

The invention accordingly comprises the several steps and the relationof one or more of such steps with respect to each of the others, and theapparatus embodying features of construction, combinations of elementsand arrangement of parts that are adapted to affect such steps, all asexemplified in the following detailed disclosure, and the scope of theinvention will be indicated in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the invention, reference is made tothe following description and accompanying drawings, in which:

FIG. 1 is a block diagram of an inventive mortar dry deliveryapplication process in accordance with an embodiment of the invention;

FIG. 2 is a small sled support mechanism constructed in accordance withan embodiment of the invention;

FIG. 3 is a large sled support mechanism in accordance with anembodiment of the invention;

FIG. 4 is a plan view of the sled support mechanism of FIG. 2;

FIG. 5 is a plan view of the sled support mechanism of FIG. 3;

FIG. 6 is a dry mortar delivery apparatus constructed in accordance withan embodiment of the invention;

FIG. 7 is a depiction of a mortar application head constructed inaccordance with an embodiment of the invention;

FIG. 8 is a depiction of an alternative mortar application headconstructed in accordance with an alternative embodiment of theinvention;

FIG. 9 is a depiction of yet another alternative mortar application headconstructed in accordance with another alternative embodiment of theinvention;

FIG. 10 is a depiction of still another alternative mortar applicationhead constructed in accordance with still another alternative embodimentof the invention;

FIG. 11 is a depiction of a sprayer head constructed in accordance withan embodiment of the invention;

FIG. 12 is a front plan view of the sprayer head of FIG. 11;

FIG. 13 is a conventional sprayer head;

FIG. 14 depicts a sprayer head constructed in accordance with analternative embodiment of the invention;

FIG. 15 depicts a sprayer head constructed in accordance with yetanother embodiment of the invention; and

FIG. 16 is a block diagram of an inventive mortar wet deliveryapplication process in accordance with an embodiment of the invention;

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The invention will now be described making reference to the followingdrawings in which like reference numbers denote like structure or steps.In accordance with various embodiments of the invention, an inventivemortar may be applied in accordance with an inventive applicationmethod, employing an inventive application apparatus in order to addressfailures in pipes or other substances where access may be limited. Suchinventive methods and systems may employ mixing of mortar materialoutside of a remediation area, delivery of one or more componentsthereof to be mixed in the vicinity of the remediation area, andpreferred final placement of mortar material to an area in which thereis limited or confined space access. The thoroughly mixed material maythen preferably be applied through a high speed centrifugal sprayer ornozzle apparatus in a manner that produces a thick to thin overlayingfully compacted, consolidated composite.

The inventors of the present invention have suggested two ways toaddress the delivery of material to a confined space with limitedaccess, as described above. Such application may take place through theuse of an inventive dry delivery process in which material is forwardedand mixed in the vicinity of the remediation area, or through the use ofan inventive wet delivery process in which material is mixed outside theremediation area, and then forwarded to the remediation area. Each ofthese processes will now be described.

Mortar Dry Delivery Process

Referring first to FIG. 1, a system for performing the inventive mortardry delivery application process is shown. Dry powder and other materialrequired for application of rehabilitation material is preferably storedin a material hopper 1000. While only one material hopper is displayed,it should be understood that multiple material hoppers or other holdingmechanisms may be employed to hold larger amounts of material, or tohold different materials that are not yet to be mixed together. Alsoshown in a support truck 1010 (or other support mechanism, i.e. train,etc.). The support truck preferably provides cranes and other mechanicalassistance as may be necessary, and further (as will be described below)preferably operates a harness employed to properly position a sprayingmechanism. As noted, any type of support mechanism may be employed thatprovides sufficient mechanical and other support (electrical, etc.).

As is further shown in FIG. 1, material hopper 1000 may be coupled witha material supply line 1020 for providing material from material hopper1000 to a sled 1030. Support truck 1010 may be further coupled to aharness 1025, preferably including at least a means for moving sled1030, such as a chain, cable or the like. Harness 1025 may also includewater, air and other materials to be delivered to sled 1030.

Sled 1030 is further preferably formed with a mixer/pump mechanism 1040and a spray head 1035. Sled 1030 is also preferably formed with supportmeans for supporting the sled within a remediation area 1050 such as apipe or the like. Sled 1030 is therefore preferably formed with one moreskis or the like for easily traversing many materials, such ascorrugated metal, concrete, cracked or damaged materials, or evenprevious layers of remediation materials if multiple layers are to beapplied. Wheels or other means of support and allowance of motion of thesled may also be provided.

During operation, sled 1030 is preferably placed at a location withinremediation area 1050 in which remediation is to begin. Such remediationarea typically may comprise a start of a section of pipe or the like.Support truck preferably pulls sled 1030 in the direction indicated byarrow A at a predetermined rate of speed in accordance with the desiredthickness of rehabilitation material to be deposited along remediationarea 1050. While moving, a spray head 1035 is preferably oscillated inthe directions indicated by arrow B, thus providing a feathering effectof the rehabilitation material within remediation area 1050.

Mixer/pump 1040 provides for the mixing of dry rehabilitation materialfrom material hopper 1000 (or of other dry or wet materials from othermaterial hoppers), along with air, water and the like from harness 1025,other air or water intake mechanisms, or from any other availablesource. As will be described below, use of such an inventive mixing-pumpand sled combination allows for the deployment of one or more inventivespray heads in accordance with embodiments of the present invention.

Referring next to FIG. 2, an inventive sled in accordance with anembodiment of the invention is shown. As is show in FIG. 2, a sled ispreferably formed of a support system 210 and a mortar handling system250. Support system 210 is further formed of one or more support framepieces 220, 221 (among other support frame pieces) and wheels 225 forsupporting support frame pieces 220 221, and allowing for movementthrough a remediation area, such as a pipe or the like. As noted above,skis, feet, or other support points allowing for movement of the sledrelative to the remediation area may further be employed. FIG. 3 depictsa larger sled, including a larger support system 310, employing supportframe pieces 320, 321, as well as internal frame portions 322, allowingfor the positioning of mortar handling system 250 nearer to a centerposition (radially) with respect to a larger remediation area or pipe,or in any other desired location. FIG. 4 depicts a side plan view of thesmaller sled of FIG. 2, while FIG. 4 depicts a side plan view of thelarger sled of FIG. 3.

As is shown in each of FIGS. 2-5, each support system is adapted topreferentially position mortar handling system 250 at a desired locationof the remediation area, and is therefore provided with one or moreheight adjustment features as part of the support frame. Thus, as isshown in FIG. 4, support frame 210 may further comprise heightadjustment elements 211 to position upper support frame 212 relative tolower support frame 213. Additionally, as is shown in FIG. 5, supportframe 210 may further comprise height adjustment elements 211 toposition upper support frame 212 relative to lower support frame 213.Additionally, support frames 210 and 310 are preferably able to bebroken down to provide access to a remediation area that may bedifficult to reach, and then reassembled once in the proper, desiredlocation.

Referring next to FIG. 6 a dry delivery apparatus and process will bedescribed. As is shown in FIG. 6, mortar handling system 250 may furthercomprise a spinner head 610 located at or near the beginning of adischarge point of mortar handling system 250. A pump 620 is preferablypositioned adjacent spinner head 610, and is adapted to provide drymortar material thereto. A mixer 625 is positioned to provide materialto pump 620. Each of the pump and mixer comprise a portion of the mortarhandling system 250, and are similarly therefore supported by supportframes 210, 310. Mixer 625 may comprise a mixing element for combiningmaterial, and may further comprise a high shear compact mixer. A feeder630 or material surge hopper/feeder is preferably positioned inlinewithin the remediation area, such as a pipe or confined space cavity,and is preferably linked to mixer 625 for providing material thereto. Aharness connection 635 may then be provided, thus connecting anddelivering dry mortar, and preferably supplies one or more of air,water, power, and raw dry material to the equipment. A guide/drive wheel640 may be provided for guiding a direction of the sled, and for aidingin driving the sled.

Dry raw material mortar is then preferably conveyed through harness 635to feeder 630. Feeder 630 in turn preferably conveys the dry materialmortar to mixer 625; the mixer mixes any such received material withwater and perhaps one or more other materials to be mixed therewith (aswill be described in greater detail below) and then pumps, via pump 620,the material through a discharge spray mechanism, such as spinner 610.

The dry mortar material may be provided as a powder comprisingrehabilitation material or the like may be delivered to a jobsite orother application location in small 25 lb to 100 lb breakable bags, 500lb to 3000 lb bulk super sacks, or in bulk pneumatic tankers. Othermethods of delivery may also be employed.

The following exemplary material and devices may preferably be employedin accordance with application of one or more of the exemplary variousembodiments of the invention, although any other combination of elementsmay be employed:

-   -   Large volume air compressor with a minimum output of 100 C.F.M,        but any desired compressor may be employed    -   Large generator capable of minimum 220v output, or any other        power amount may be employed.    -   Water storage tank and pump capable of supplying adequate water        for pre-washing of application area and batch water for        material. Minimum 500 gallon, or any necessary amount.    -   Material storage bin or hopper with attached blower capable of        receiving and pneumatically delivering the dry bulk material to        the Feeder.    -   A crane or winch capable of lifting all equipment in and out of        confined space as well as loading and unloading bag and super        sack raw materials.

A current commercially available spinner head may be employed todischarge and direct a thick to thin spray or application coating ofrehabilitation material (such as that shown in FIG. 7), including aproprietary blend of GeoSpray™ and GeoSpray™ AMS geopolymer mortars. Inaccordance with the invention, however, it is desirable to apply a ¼″inch or less to 6 inch thick or greater coating in a single completepass, without any hand trowel or finishing required, to a surface to berehabilitated, such as to the inside of a concrete pipe, metal pipe, orthe like. There are preferably three sizes of spinner heads currentlyavailable, including a 1″, 1½″, and 2″ inline feed, although theinvention shall not be so limited and may be employed with any sizedspray head. These exemplary spinner heads may be employed as follows:

-   -   1″ spray 12″ to 102″ diameter pipe    -   1½″ spray 30″ to 144″ diameter pipe    -   2″ Spray 42″ to 180″ diameter pipe

While there are a variety of conventional spinner shafts and headsavailable, none of these spinner heads have been found to be capable ofachieving a desired “Thick to Thin” spray configuration desired to buildthe thicknesses desired, in accordance with the various embodiments ofthe present invention. Therefore, in accordance with one or moreembodiments of the invention, one or more inventive modified spinnerheads may be provided. Such a modified orifice or spinner head maycomprise one or more trapezoidal openings in a spinning cylinder thatdelivers rehabilitation material in a manner which thickly applies alarger volume of material then overlays the thicker volume with athinner finer spray as the spinner head is moved back through the pipeor confined space.

Referring first to FIG. 7, a spinner head 120 employing trapezoidalorifices 125 is shown, and compared to a conventional spinner head 110employing rectangular orifices 115. As is shown in FIG. 7, conventionalspinner head 110 is mounted in such a manner as to rotate about an axis,denoted at “Arrow A.” As rotated in such a manner, mortar or othermaterial may be expelled from the one or more rectangular orifices 115.As is evident from FIG. 1, material will be evenly provided to asurface, such as the inside of a pipe to which the mortar is to beapplied from the one or more rectangular orifices 115. As such aconventional spinner head is moved back and forth in the directionindicated by Arrow A (or opposite the direction indicated by Arrow A),material will be evenly and continuously applied. The inventors of thepresent invention have determined, however, that it may be advantageousto first apply a heavier layer of mortar material, followed by athinner, finer layer of such mortar material. Thus, the use of theinventive spinner head 120 employing trapezoidal orifices 125 maypreferably apply a varying thickness of mortar or other material. Suchtrapezoidal orifice shapes allow for the above-noted thinner layer ofmaterial upon removal of the spinner head from the pipe or otherapplication surface through movement in the direction indicated by ArrowB. As the orifices move back and for the in the direction indicated byArrow B (or opposite the direction indicated by Arrow B), and eventuallyaround a central support point, such as a material supply pipe or thelike (as will be described below), trapezoidal orifices 125 allow forcontrol of the amount of material applied to different surfaces. Uponremoval of the inventive spinner head 120 from such a pipe or the like,the thinnest portions of trapezoidal orifices 125 will spray materialinto the pipe last at each point therein, thus providing a finer,thinner application of mortar on top of any thicker layer of mortar orother material.

FIG. 8 shows a similar inventive spinner head 220 including elongatedtrapezoidal orifices 225, and once again as compared to a conventionalspray head 110. Such elongation creates a larger spray zone, thusenabling the delivery of material to be fanned out further gaininggreater coverage, while providing the benefits of the embodimentdescribed above with respect to FIG. 7. Such an extended spinner headwill preferably allow for a sustained build up of material as thespinner head is moved back through the pipe or confined space in thedirection indicted by “Arrow C” (and upon rotation about an axisindicated thereby) while still allowing for the application of athinner, finer layer of mortar material when desired.

FIG. 9 shows an alternative embodiment of an inventive spinner head 320including a conventional portion 310 including conventional rectangularorifices 315, and a conical section portion 330 including trapezoidalorifices 335 (or alternatively, rectangular, triangular, or otherdesirably-shaped orifices positioned along the conical portion 330). Theuse of such a spinner head allows for the even, bulk application ofmortar material as in the conventional spinner head 110, and furtherallows for the benefits of the use of trapezoidal orifices in order toprovide a thinner, finer application of mortar upon the removal of thesprayer head. In such a manner a benefit in the type and consistency ofmortar applied may be provided, thus providing a thinner applicationadjacent the cone end (335) of the spinner head spinner top.

Finally, FIG. 10 shows a combination of an elongated portion of aspinner head 410 including rectangular orifices 415, and including aconical section top 430, employing one or more trapezoidal orifices 435,in accordance with yet another alternative embodiment of the invention.This embodiment of the inventions thus provides the benefits of theembodiments described in connection with FIG. 9, and further providesthe benefits of the elongated embodiment described in connection withFIG. 8.

Any of these inventive or conventional spinner heads may be employedwith one or more of the following embodiments of the invention,depicting various inventive mortar delivery systems. FIG. 14 presents afirst of such inventive mortar delivery systems, and comprises amodification to the conventional spinner head assembly depicted in FIG.13, and includes an additional intake line 850 being coupled to materialdelivery device 710 via a coupler 860 for delivery or air or any otherdesirable material to the spinner head via the mortar delivery system.Any of the spinner heads described above with respect to FIGS. 7-10 (orany conventional spinner head) may be employed in accordance with theembodiment of FIG. 14. Therefore, in accordance with this embodiment ofthe invention, an additional intake line is introduced to allow for theaddition of further material to the material intake line via the coupler860. The additional intake line is preferably placed at a radial centerof material delivery device 710. Preferably, this additional intake lineis open ended and may be terminated in a position in the vicinity of thespinner head, or the spinner disk, preferably just before reaching theseportions of the apparatus, and further in the vicinity of the materialdischarge location 712. As described, any air and/or other materialprovided via the additional intake line 850 preferably exits out of theintake line in a manner that evenly spreads high pressure, high volumeair and/or other material across the rear spinning discharge disk 714,and thus may be combined at that point with any mortar or other materialbeing delivered via material delivery device (tube) 710. In accordancewith this embodiment of the invention, the spinning disk may be modifiedin a manner so that it is adapted to receive the air and/or othermaterial evenly and redirect the flow thereof along the inside face ofthe spinning discharge disk.

In accordance with this additional embodiment of the invention, one ormore of the following benefits may be realized. First, various materialdischarge properties may be altered. In particular, material dischargevolume may decrease, and oxidation of materials may increase. Air and/orany other desired materials may be introduced at the discharge point.Speed of the discharged material may increase, while the pattern of thedischarged material may change. In particular, a larger number ofsmaller particles may be discharged, and these solid particles may bemore evenly dispersed within a more definitive pattern. Next, materialmay be propelled by entering into a high velocity directed air stream,or stream of other desirable material, and will not simply becentrifugally discharged. Further, there may be less wear on theequipment during repeated use. The material will move in accordance withair or other material flow, resulting in reduced material to metalfriction on the spinner head so that the spinner will operate moreconsistently and evenly while more air will be demanded by the spinnermotor. In addition, it is contemplated that as a result, any sealsemployed by the spinner head will last longer. Finally, such aninventive apparatus will enable additional regulation of remediationmaterial flow via a control mechanism not currently achievable using themore typical prior art systems.

Referring next to FIG. 15, a further alternative embodiment of theinvention is shown, and includes delivery of air around the perimeter ofthe material supply pipe. Thus, as is shown in FIG. 15, this alternativeembodiment includes an additional intake line 950 being coupled tomaterial delivery device (pipe) 910. The original air intake 730 may beemployed in order to propel the spinner head in a pneumatic matter. Anyof the spinner heads described above with respect to FIGS. 7-10 (or anyconventional spinner head) may be employed in accordance with theembodiment of FIG. 15. Therefore, in accordance with this embodiment ofthe invention, an additional air intake line is preferably introduced toallow for the addition of air to be supplied around the perimeter(coaxially) to material supply device 910. The additional air intakeline 952 is thus preferably placed around, and substantially coaxiallyto, material delivery device 910. Preferably, this additional air intakeline is open ended and may be terminated in a position in the vicinityof the spinner head, or the spinner disk 920, preferably just beforereaching these portions of the apparatus, and further in the vicinity ofthe material discharge location 912. Spinner disk 920 is preferablyformed with material supply device 910 passing therethrough, and airintake line terminating at air discharge ports 953 formed therein. Pins913 are provided for positioning a rear spinning discharge disk 914 adesired distance from spinner disk 920. Rear spinning discharge disk 914may be formed with a protrusion 916 for the direction of suppliedmaterial and air radially outward from the spinner head. An additionaldirectional member 915 (circularly provided, but triangular in crosssection) may be provided for further directing the supplied material andair. As described, any air and/or other material provided via theadditional air intake line 952 preferably exits out of the intake linein a manner that evenly spreads high pressure, high volume air and/orother material across the rear spinning discharge disk 914. Inaccordance with this embodiment of the invention, the spinning disk maybe modified in a manner so that it is adapted to receive the air and/orother material evenly and redirect the flow thereof along the insideface of the spinning discharge disk. Any number of intake lines 952 maybe provided to allow for the supply of air or other materials.

The following additional benefits may be enjoyed in accordance with thisembodiment of the present invention. The introduction of high volumehigh pressure air and/or other materials at a discharge point may beachieved. The material may be projected or propelled at a high velocityusing an uninterrupted directional air stream. The high velocitymaterial is preferably shot out in a manner which achieves a highvelocity and impact achieving a greater physical packing or density. Thepropelled material preferably achieves high density which positivelyaffects the mortar performance and durability. Benefits may result inmortar that is more resistant to chemical attacks, is more imperviousand has improved compressive strength. Additionally, a greater diameterplacement may be achieved while providing an improved consistency offinal product.

Therefore, as is described in FIG. 15, an intake line is introduced intothe material in flow fitting, and is preferably placed around theperimeter of the material intake line, and coaxially thereto. The intakeline preferably terminates just before the end spinner head or spinnerdisk and discharges a high velocity of pressured air through 3/16″ + or− ⅛″ diameter orifices, although any sized orifices may be employed.

As a result, the air and/or other material exits out of the intake linein a manner which evenly spreads high pressure high volume air and/orother material across the rear spinning discharge disk. The spinningdisk discharge is preferably constructed in a manner which receives theair and/or other material evenly and redirects the flow along the insideface of the spinning discharge disk, through the use of protrusion 916and directional member 915. The air and/or other material is sprayed outin a 360 degree pattern (or other pattern as desired) at high speed andpressure. Mortar is pumped through the center material intake line 910and is pushed into this air stream. The mortar is combined with the airand/or other additives, introduced in accordance with one or moreintakes 950, or through a single intake 950.

Furthermore, material discharge properties will be altered in thatmaterial discharge volume will decrease while oxidation of materialswill increase. Air and/or other materials will be introduced at thedischarge point. The speed of the thrown material will increase whilethe pattern of the material thrown will change: a larger number ofsmaller solid particles will be shot or propelled while solid particleswill be more evenly dispersed within a more definitive pattern. Materialwill be propelled by entering into a high velocity directed air streamand not just physically flung centrifugally. As a result, there will beless wear on the equipment, material will move on air, resulting inreduced material to metal friction on the spinner head. The spinner willrun more consistently and evenly, air demand by a system motor will bemore even, and seals will last longer. This improved inventive apparatuswill enable an additional regulation or control mechanism not currentlyavailable.

In accordance with an alternative embodiment of the invention, and asdescribed above, any of the described inventive mortar delivery systemsmay be coupled with one or more of the described inventive sleds to beused as the foundation mount and transport vehicle for any type ofinventive spinner or spray nozzle. The sled may further act as thefoundation or mount of the described mixture and delivery system.Therefore, in accordance with the invention, such a sled may be providedthat smoothly moves through a pipe or other confined space so that thespinner head preferably travels along a substantially level path. Thesled may pass through the pipe at any portion of the diameter thereof,the sled may preferably pass at substantially the center most point of apipe or cavity, through the user of various positioning elements, asdescribed above. An air activated or hydraulically activated set oftracks that may be controlled by the volume of mortar material beingsprayed is preferably employed for maintaining a location andpositioning of the sled. Furthermore, the above-described method inwhich the spinner head may oscillate forward and backward at evenintervals and distance along a horizontal plain creating an oscillatingspray point allowing the buildup of material to the greatest thicknessin a single pass may be employed. A reciprocating arm may be providedthat moves the spinner head forward and backward along a cylinder, thecylinder preferably supplying the mortar to the spinner (see FIGS. 2-6).Thus as is shown in FIG. 3, for example, in this particular embodiment,one or more linkage arms 330 may be coupled to a point other than acentral point of a cylinder 335, thus imparting a reciprocating motionto the linkage arms 330. This reciprocating motion is preferablytransferred to the spray head resulting the described oscillatingmotion. Of course any method of oscillating the spray head may beemployed. This movement preferably allows for a stroke or distance ofany desired amount, and preferably from a minimum of 3″ to a max of 48″stroke or distance. In alternative embodiments of the invention,movement of the spinner head in a reciprocating axial direction allowsfor the application of multiple layers of material during oneapplication, thus aiding in generating a thickness of rehabilitationmaterial as desired. Use of such an oscillating spray head may allow forthe buildup of materials in layers, providing a laminating effect.Benefits of this oscillating spray head motion may include an evenoxidation of materials throughout the entire applied mass of material,an ability to build up a greater thickness of material while providinggreater control over the applied thickness of the materials as well asgreater control over the distribution of the materials. Such anoscillating spray head further allows for an even distribution ofadditives through the mass of applied materials and finally maycompensate for any irregularity in the movement of the sled.

A mixture and delivery system allows a liquid admixture to be sprayedinto the material stream, the combined material then being sprayed fromthe spinner head. Thus, as such rehabilitation material is output fromthe spinner head, liquid or other material may be added to the materialstream.

Additional embodiments of the invention may employ the above describedmixer for mixing material in a confined space or pipe, such as within oradjacent to the remediation area, thus allowing for the combining of drypowder and liquid, etc. in order to provide a desired mixture ofrehabilitation material. A feeder may also be provided to receive,store, and feed material to an inline mixer. It may be considered theengine or locomotive used to move the whole train of equipment throughthe lines, and may comprise a control center of the apparatus. Aharness, as described above, may be provided, connecting and deliveringall components together, and may preferably supply air, water, power,and raw dry material to the equipment.

Mortar Wet Delivery Process

In accordance with an alternative embodiment of the invention, a wetdelivery process for mortar application may be employed. Referring firstto FIG. 16, a system for performing the inventive wet delivery of mortarfor application is shown. Dry powder and other material required forapplication of rehabilitation material is preferably stored in amaterial hopper 2000. While only one material hopper is displayed, itshould be understood that multiple material hoppers or other holdingmechanisms may be employed to hold larger amounts, or to hold differentmaterials that are not yet to be mixed together. Also shown in a supporttruck 2010 (or other support mechanism, i.e. train, etc.). The supporttruck preferably provides cranes and other mechanical assistance as maybe necessary, and further (as will be described below) operates aharness employed to properly position a spraying mechanism. As noted,any type of support mechanism may be employed that provides sufficientmechanical and other support (electrical, etc.).

As is further shown in FIG. 16, material hopper 2000 is coupled with amixer/pump 2040 for mixing the dry power supplied in hopper 2000 withwater and other materials as desired. Mixer/pump 2040 may be coupled tomaterial supply line 2020 for providing material from material hopper2000 to a sled 2030. Support truck 2010 is preferably further coupled toa harness 2025, preferably including at least a means for moving sled2030, such as a chain, cable or the like. Sled 2030 is preferably placedwithin a remediation area, such as a pipe 2050 or the like.

In accordance with various embodiments of the invention, powder, such asa dry remediation material, may be delivered to the jobsite in small 25lb to 100 lb breakable bags, 500 lb to 3000 lb bulk super sacks, or inbulk pneumatic tankers, or other appropriate delivery vessel. A“spinner” or spray head may be located at or near a beginning dischargepoint of a surface to be rehabilitated. A particular inventive spinnerto be employed with this mortar wet delivery process will be describedbelow. Similar to the embodiment depicted in FIG. 1, a “sled” orspraying equipment may be transported into a pipe or confined spacecavity. The spinner is preferably attached to the sled. Remediationmaterial is preferably discharged into a pump capable of pumping thethick slurry mortar through a line (Part of the harness) which isattached to the spinner head. The harness is preferably attached to theremaining apparatuses, and preferably delivers one or more of thefollowing: electric, water, air, dry mortar, wet mortar, hydraulic tothe sled and spinner head. The air and mortar (and any other suppliedmaterials) are preferably combined at the point of spray generating anair sprayed material.

Material preferably employed in such an implementation may include alarge volume air compressor with a preferable minimum output of 100C.F.M, or other desirable output, a large generator capable of minimum220v output, or other desirable output, and a water storage tank andpump capable of supplying adequate water for pre-washing of applicationarea and batch water for material. Preferably Minimum 500 gallon, orother desired amount. One or more material storage bins or hoppers withattached blowers capable of receiving and pneumatically delivering thedry bulk material to the feeder may also be employed. A mortar mixer,concrete pump, and a crane or winch capable of lifting equipment in andout of confined space as well as loading and unloading bag and supersack raw materials may also be employed

In accordance with such an embodiment of the invention, a new materialspinner head design may be employed, avoiding the need for a motor orother spinning device for the application of wet remediation material.In such a novel spinner head, remediation material may be combined withair or high pressure air which accelerates or shoots the material at ahigh velocity. Such high pressure air and remediation material mixturemay turn a turbine or fin configuration spinner head, thus creating aspinning motion. The spinning motion preferably turns key dischargepoints. (Similar to a sprinkler head which uses the water pressure tospin the head). The high pressure material with high pressure airpreferably work together to both spin the head and spray the materialwith a high pressure and material impact.

Such an inventive nozzle is shown in FIGS. 11 and 12. As is shown inFIG. 11, a nozzle 500 spins about an axis 510, comprising a hose ofother material delivery device. Upon delivery of material at a highspeed, such material is preferably ejected at a high velocity from oneor more angled ejection ports 520, the direction of these ports movingnozzle 500 about axis 510 upon the ejection of such material. Thus,through the ejection of such material through these angled ejectionports, a rotational motion is applied to the spinner head, in additionto ejecting the material. The combined material therefore generatesrotational motion of the spinner head while also applying the combinedmaterial as desired. Such a nozzle may be employed with any of theorifice designs described above. FIG. 12 further depicts an injectiontube 530 for allowing the injection of any desired material, and amixing chamber 540 for mixing material from hose 510 and injection tube530.

Therefore, in accordance with various embodiments of the invention,apparatuses and methods are provided allowing for a uniform, thickmixture of remediation material to be provided to a surface to beremediated, such as the internal surface of a pipe or other surface orspace.

It will thus be seen that the objects set forth above, among those madeapparent from the preceding description, are efficiently attained and,because certain changes may be made in carrying out the above method andin the construction(s) set forth without departing from the spirit andscope of the invention, it is intended that all matter contained in theabove description and shown in the accompanying drawings shall beinterpreted as illustrative and not in a limiting sense.

It is also to be understood that this description is intended to coverall of the generic and specific features of the invention hereindescribed and all statements of the scope of the invention which, as amatter of language, might be said to fall there between.

1. A spray head for spraying mortar, comprising: a mortar supply pipe; aspinning head positioned at an outlet point of the mortar supply pipe,the spinning head directing mortar supplied from the mortar supply pipein a direction substantially perpendicular to the direction of travel ofmortar in the mortar supply pipe; an air intake for receiving air, theair being employed to spin the spinning head pneumatically; a materialinput port for inputting material to be combined with the mortar in themortar supply pipe at the outlet point of the mortar supply pipe.
 2. Thespray head of claim 1, wherein the material input port is providedcoaxial to the mortar supply pipe.
 3. The spray head of claim 2, whereinthe material input port is provided inside the mortar supply pipe. 4.The spray head of claim 2, wherein the material input port is providedaround the mortar supply pipe.
 5. The spray head of claim 4, furthercomprising a plurality of nozzles at the output point of the mortarsupply pipe.
 6. The spray head of claim 1, further comprising one ormore trapezoidal orifices on the spray head.
 7. The spray head of claim5, further comprising one or more additional rectangular orifices.
 8. Aspray head for spraying mortar, comprising: a mortar supply pipe; and amaterial input port for inputting material to be combined with themortar in the mortar supply pipe at the outlet point of the mortarsupply pipe.
 9. The spray head of claim 8, wherein the materialcomprises air.
 10. The spray head of claim 9, wherein the materialfurther comprises liquid.
 11. The spray head of claim 8, wherein thematerial input port is provided coaxial to the mortar supply pipe. 12.The spray head of claim 11, wherein the material input port is providedinside the mortar supply pipe.
 13. The spray head of claim 11, whereinthe material input port is provided around the mortar supply pipe.
 14. Aspray head for spraying rehabilitation material to a remediation area,comprising: a mortar supply pipe; and a spray head, the spray headfurther comprising one or more angled mortar ejection ports for ejectingmortar therethrough, the ejection of the mortar causing the spray headto spin.
 15. The spray head of claim 14, wherein the mortar is ejectedin a direction substantially perpendicular to the direction of deliveryof mortar through the mortar supply port.
 16. The spray head of claim14, further comprising an air intake port, air received via the airinput port aiding in spinning the spray head.